Devices, Systems And Method For Flooring Performance Testing

ABSTRACT

In one implementation, a footfall detection assembly comprising a sensor underlayment unit and a data analysis device is provided. The sensor underlayment unit comprises a sensor having a unique sensor identifier and a plurality of zones, wherein the sensor is configured to measure zone capacitance in of the plurality of zones, and a processing unit operably connected to the sensor. The processing unit is configured to receive the measured zone capacitance values from the sensor upon the occurrence of a change in measured zone capacitance of the sensor and generate and transmit a data packet comprising at least the unique sensor identifier and measured zone capacitance values upon occurrence of a change in capacitance of at least one of the plurality of zones of the sensor. The data analysis device is configured to receive the data packet, compare the measured zone capacitance values of the data packet to previously-measured zone capacitance values associated with the sensor underlayment into and generate a result therefrom.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/834,386, filed Jun. 7, 2022, which is a continuation of U.S. patentapplication Ser. No. 16/861,693, filed Apr. 29, 2020, now U.S. Pat. No.11,371,922, which is a continuation of U.S. Patent Application No. filedAug. 10, 2017, now U.S. Pat. No. 10,684,204, which is a continuation ofU.S. patent application Ser. No. 14/660,647, filed Mar. 17, 2015, nowU.S. Pat. No. 9,766,171, which claims the benefit of U.S. ProvisionalPatent Application No. 61/954,463, filed Mar. 17, 2014. Each of theseapplications is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION The Field of the Invention

Implementations described herein relate generally to a footfalldetection assembly to measure flooring performance and useful life aswell as associated systems and methods.

Background

Flooring performance testing is an important aspect of the flooringindustry and, particularly, the carpeting industry. For example, carpetsare generally expected to last from about 5 to about 10 years and areusually sold with a warranty based, at least partially, on the expectedwear performance over time. Currently, wear testing is performed usingeither contract walking or mechanical tumblers. Contract walkinginvolves lining a floor with a plurality of 9″ by 22″ carpet samples andhaving the contract walkers complete, e.g., 20,000 pedestrian laps overthe plurality of samples. A contract walker will step in differentlocations on the 9″×22″ sample as they do the walk test. While contractwalking has the benefit of replicating real-world conditions, it is acostly and slow testing method. Mechanical tumbling, an alternative tocontract walking, involves placing the carpet samples on the innersurface of a rolling drum and placing a weight inside that is configuredto tumble on the carpet samples as the drum is rotated, thereby inducingwear. Mechanical tumbling is cheaper and faster than contract walkingbut does not readily correlate to real-world conditions. In either case,trafficked carpet samples are then graded, e.g. on a visual scale from1-5. Such grading scales are subjective and do not lend themselves toclearly communicating the relative performance of different flooringsamples.

Accordingly, a need exists for improved devices, systems and method forflooring performance testing that provide for improved accuracy inpredicting field performance of flooring samples, that allow measurementat a reduced cost compared to current methods, and that enable effectivecomparisons between the performance of different flooring choices.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

In one aspect, the present disclosure provides for a footfall detectionassembly comprising a sensor underlayment unit and a data analysisdevice. The sensor underlayment unit comprises a sensor having a uniquesensor identifier and a plurality of zones, wherein the sensor isconfigured to measure zone capacitance in each of the plurality ofzones, and a processing unit operably connected to the sensor andconfigured to receive the measured zone capacitance values from thesensor and generate and transmit a data packet comprising at least theunique sensor identifier and the measured zone capacitance values uponoccurrence of a change in capacitance of the sensor and time stamp.

In another aspect, the present disclosure provides for a system fordetermining flooring performance comprising a plurality of sensorunderlayment units, a data archival device configured to receive andstore a data packet generated by the sensor underlayment unit and a dataanalysis device configured to receive the stored data packets, comparethe zone capacitance to a previously measured zone capacitance valuesand generate a result therefrom.

In another aspect, the present disclosure provides for a method fordetermining flooring performance comprising installing a footfalldetection assembly, installing a flooring for testing comprising aplurality of samples on top of the footfall detection assembly,providing a means for inducing foot traffic wear, removing one sample ofthe plurality of samples after a series of a selected numbers of footstrikes, measuring the one sample with at least one of a spectralmeasurement device and an imaging device at preselected angles todetermine the viewing angle that produces the greatest color change ascompared to a control sample, and determining the number of foot strikesthe flooring sample can absorb until a threshold change in at least oneof color and texture occurs.

In another aspect, the present disclosure provides for a method formeasuring the number of foot strikes a flooring sample can absorb untila threshold change in at least one of color and texture occurscomprising providing a spectrometer having an incident light beam,providing a flooring sample for measurement, providing a control samplehaving a control pile direction, determining a flooring sample piledirection, orienting the flooring sample with respect to thespectrometer such that the incident light beam is preferentiallyoriented relative to the sample pile direction and measuring theflooring sample with the spectrometer at preselected angles todetermining the viewing angle that produces the greatest color change ascompared to the control sample.

Additional features and advantages of exemplary implementations of theinvention will be set forth in the description which follows, and inpart will be obvious from the description, or may be learned by thepractice of such exemplary implementations. The features and advantagesof such implementations may be realized and obtained by means of theinstruments and combinations particularly pointed out in the appendedclaims. These and other features will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate aspects and together with thedescription, serve to explain the principles of the methods and systems.

The Figure illustrates a schematic drawing of one implementation of afootfall detection assembly according to the present disclosure.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawing, and claims, and theirprevious and following description. However, before the present devices,systems, and/or methods are disclosed and described, it is to beunderstood that this invention is not limited to the specific devices,systems, and/or methods disclosed unless otherwise specified, as suchcan, of course, vary. It is also to be understood that the terminologyused herein is for the purpose of describing particular aspects only andis not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known aspect. To thisend, those skilled in the relevant art will recognize and appreciatethat many changes can be made to the various aspects of the inventiondescribed herein, while still obtaining the beneficial results describedherein. It will also be apparent that some of the desired benefitsdescribed herein can be obtained by selecting some of the featuresdescribed herein without utilizing other features. Accordingly, thosewho work in the art will recognize that many modifications andadaptations to the present invention are possible and can even bedesirable in certain circumstances and are a part described herein.Thus, the following description is provided as illustrative of theprinciples described herein and not in limitation thereof.

Reference will be made to the drawings to describe various aspects ofone or more implementations of the invention. It is to be understoodthat the drawings are diagrammatic and schematic representations of oneor more implementations, and are not limiting of the present disclosure.Moreover, while various drawings are provided at a scale that isconsidered functional for one or more implementations, the drawings arenot necessarily drawn to scale for all contemplated implementations. Thedrawings thus represent an exemplary scale, but no inference should bedrawn from the drawings as to any required scale.

In the following description, numerous specific details are set forth inorder to provide a thorough understanding described herein. It will beobvious, however, to one skilled in the art that the present disclosuremay be practiced without these specific details. In other instances,well-known aspects of flooring performance testing have not beendescribed in particular detail in order to avoid unnecessarily obscuringaspects of the disclosed implementations.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Ranges may be expressed herein as from “about” oneparticular value, and/or to “about” another particular value. When sucha range is expressed, another aspect includes from the one particularvalue and/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another aspect. It will befurther understood that the endpoints of each of the ranges aresignificant both in relation to the other endpoint, and independently ofthe other endpoint.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where said event or circumstance occurs and instances where itdoes not.

Throughout the description and claims of this specification, the word“comprise” and variations of the word, such as “comprising” and“comprises,” means “including but not limited to,” and is not intendedto exclude, for example, other additives, components, integers or steps.“Exemplary” means “an example of” and is not intended to convey anindication of a preferred or ideal aspect. “Such as” is not used in arestrictive sense, but for explanatory purposes.

As used in the description and claims, references to “color change”,“change in color” and variants thereof should be construed to includeany color change between an untrafficked flooring sample and atrafficked flooring sample that is measurable by any technique known inthe art, such as but not limited to, colorimetric methods,spectrophotometric methods, and the like. As used in the description andclaims, references to “texture change”, “change in texture” and variantsthereof should be construed to mean any observable change in texturebetween an untrafficked flooring sample and a trafficked flooring sampleand can include changes in texture due to damaged yarn tips, changes inyarn orientation relative to the flooring surface, and the like. As usedin the description and claims, the term “appearance change” as appliedto a flooring sample refers to a combination of the color change andtexture change of a trafficked flooring sample relative to anuntrafficked flooring sample.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutation of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be predefined it is understood that each ofthese additional steps can be predefined with any specific aspect orcombination of aspects of the disclosed methods.

Implementations described herein are directed toward, devices, systemsand methods for flooring performance testing. In one aspect, 22 foot by9 foot flooring comprising a plurality of flooring samples can beinstalled in a room for testing per applicable ASTM test methods. Theflooring can be installed over a footfall detection assembly. Thefootfall detection assembly can comprise a sensor underlayment unit anda data analysis device. In one aspect, the sensor underlayment unit cancomprise a sensor having a unique sensor identifier and a processingunit operably connected to the sensor. It is contemplated that thesensor can further comprise a plurality of zones, wherein the sensor isconfigured to measure zone capacitance in each of the plurality ofzones. In other aspects, the processing unit can be configured toreceive the measured zone capacitance values from the sensor andgenerate and transmit a data packet comprising at least the uniquesensor identifier and measured zone capacitance values upon occurrenceof a change in capacitance in at least one of the plurality of zones ofthe sensor. It is also contemplated that the data analysis device can beconfigured to receive the data packet, compared the measured zonecapacitance values of the data packet to previously-measured capacitancevalues associated with the sensor underlayment unit and generate aresult therefrom. It is contemplated that measured capacitance changesin each of the plurality of zones corresponds to at least one footstrike event. In one aspect, the sensor can be of the pressure platetype and, in a further aspect, multiples or arrays of these sensors canbe installed in a grid pattern so the actual foot strike locations andtotal number of strikes per location can be measured, recorded andanalyzed. In another aspect, the sensor can be a light curtain assemblyconfigured to allow more precise locations of foot falls to bedetermined, as well as the total number of foot strikes per a given areain the walking space.

In yet other aspects, at least one of the plurality of samples can beprocessed through the above steps, using increments of foot trafficexposure, followed by measurement via an imaging device relative to anun-trafficked sample, in order to determine how many foot strikes thecarpet can absorb without a noticeable change in at least one of coloror texture. It is contemplated that the feedback from the abovemeasurements can be used to improve flooring constructions with anemphasis on resistance to color and/or texture change induced by foottraffic. After the flooring sample is tested, it is contemplated thatthe resultant quality data can be used to improve the resiliency,wear-ability and life of the floor covering. In light of the presentdisclosure, one skilled in the art will appreciate that the resultantdata can allow a floor covering manufacturer to optimize floor coveringcharacteristics such as, for example and without limitation, twistlevels, denier per filament, polymer types, fiber cross sections and thelike in accordance with the present disclosure. In another aspect, theabove measurements can be used as a communication tool to flooringcustomers, as a way to forecast the expected lifespan of a given floorcovering product in relation to other floor covering products. In lightof the present disclosure, one skilled in the art will appreciate thatthe footfall detection assembly and associated methods disclosed hereinwill enable a flooring manufacturer to more accurately engineer theusable life of a flooring, and allow warranties to better approximatethe reality of wear and abrasion.

In the following description, numerous specific details are set forth inorder to provide a thorough understanding described herein. It will beobvious, however, to one skilled in the art that the present disclosuremay be practiced without these specific details. In other instances,well-known aspects of flooring performance testing have not beendescribed in particular detail in order to avoid unnecessarily obscuringaspects of the disclosed implementations.

Turning now to the Figure, an implementation of one exemplary aspect ofa footfall detection assembly is illustrated. In one aspect, a footfalldetection assembly 100 having a sensor underlayment unit 102 and a dataanalysis device 104. The sensor underlayment unit 102 comprises a sensor106 having a unique sensor identifier and a plurality of zones 108,wherein the sensor is configured to measure zone capacitance in each ofthe plurality of zones, and a processing unit 110 operably connected tothe sensor 106 and configured to receive the measured zone capacitancevalues from the sensor and generate and transmit a data packetcomprising at least the unique sensor identifier and the measured zonecapacitance values upon occurrence of a change in capacitance of atleast one of the plurality of zones of the sensor. In another aspect,the sensor underlayment unit can comprise a power supply bus 112configured to supply the sensor 106 and processing unit 110 with power.In another aspect, the data analysis device 104 can be configured toreceive the data packet, compare the measured zone capacitance values ofthe data packet to previously-measured zone capacitance valuesassociated with the sensor underlayment unit and generate a resulttherefrom. It is also contemplated that the processing unit 110 can beconfigured to wirelessly transmit the data packet to the data analysisdevice 104 and that the data analysis device can further comprise awireless receiver operable to receive the data packet. In an alternativeaspect, it is contemplated that the data analysis device can comprise aradio frequency (RF) data logger and the processing unit can beconfigured to transmit the data packet to the data analysis device viaRF.

In one aspect, the sensor 106 can be a capacitance sensor and, infurther aspects, can be a pressure plate capacitance sensor. In otheraspects, the sensor can comprise an array of sensors. In light of thepresent disclosure, one skilled in the art will also appreciate thatother sensor types such as, for example and without limitation,capacitance thin film, retro-reflective optical, force sensitiveresistor, membrane keyboard, piezoelectric thin film, hall effect,surface acoustic wave, strain gauge, pressure switch sensors and thelike can be employed in lieu of pressure plate capacitor sensors withoutdeparting from the scope of the present disclosure.

In another aspect, the sensor 106 can comprise a plurality of zones 108.Here, the sensor can be configured to measure zone capacitance in eachof the plurality of zones. In order to reduce the overall cost of thesystem, the required data storage capacity and the real-time dataprocessing speed, the number of sensors per meter can be chosen to berelatively small and, in a further aspect, can be less than about 10. Itis also contemplated that, in more complicated systems, sensors could beas numerous and as small as the pixels of, e.g., a computer or TVscreen. In another, it is contemplated that each sensor can comprisefrom about 2 to about 12 zones, more preferably, from about 4 to about10 zones, and, most preferably, about 8 zones. In another aspect, theplurality of zones can be equally sized. In a further aspect, the zonescan be spaced radially about a center point and, optionally, can beequally sized. It is further contemplated that each of the plurality ofzones can cover substantially equal radial portions as measured from thecenter of the area of the sensor underlayment unit. It is contemplatedthat the sensor underlayment unit can cover an area of from about 0.05to about 0.50 square meters and, preferably, about 0.25 square meters.In operation, the sensor can measure zone capacitance in each of theplurality of zones. In certain aspects, the sensor can have a footprintof from about 1 to about 144 square inches. In further aspects, thesensor can have a side or diameter from about 1 to about 12 inches.

In another aspect, a data analysis device 104 can be configured tocompare the time stamp of the data packet to the time stamp of at leastone other data packet to confirm whether a foot strike is unique orassociated with the at least one other data packet. It is furthercontemplated that the data analysis device is programmed to determine ifthe measured zone capacitance values are a result of a singular externalevent or a plurality of external events. Here, the data packet furthercomprises time values that correspond to the respective measured zonecapacitance values. In operation, if the time values of respectivemeasured zone capacitance values are less than a predetermined timevalue, the data analysis device is configured to generate a singularfootfall event result. The predetermined time value can be from about 10to about 500 msec, more preferably, from about 20 to about 250 msec,and, most preferably, from about 35 to about 50 msec. However, oneskilled in the art will appreciate that the predetermined time valuedepends on the sensor technology used and, even further, the rate atwhich a given sensor can return to equilibrium.

In another aspect, the data packet can further comprise an areaidentifier. In light of the present disclosure, one skilled in the artwill appreciate that an area identifier can be used when a plurality ofsensor underlayment units are used together in a system.

It is also contemplated that the footfall detection assembly cancomprise a data archival device 114 configured to receive and store eachdata packet transmitted by the sensor underlayment unit 102. It iscontemplated that the data archival device can be operably associatedwith the data analysis device or independent from the data analysisdevice. In one aspect, the data archival device can comprise a RF datalogger. In another aspect, the data archival device can comprise acomputer data storage medium such as an SD card, a thumb drive, a dongleand the like. The data archival device can be further configured totransmit a plurality of stored data packets to the data analysis device104 in a periodic batch operation via, for example and withoutlimitation, a local-area network and the like.

In yet other aspects, it is contemplated that a plurality of sensors106, the processing unit 108, the data analysis device 104, and,optionally, the data archival device 114 can be integrated into onedevice. However, one skilled in the art will appreciate that the presentdisclosure does not require that the sensor 108, the sensor processingunit 108, the data archival device 114, and the data analysis device 104or any other component be constrained to separate physical entities.Accordingly, in this or any aspect disclosed herein, the components ofthe footfall detection assembly and systems thereof can take on avariety of implementations and all such implementations are within thescope of the present disclosure.

In yet other aspects, it is contemplated that a plurality of sensorunderlayment units 102 can be employed in a system for determiningflooring performance. Here, it is contemplated that a power supply buscan be operably connected to each of the sensor underlayment units.Here, a data archival device can be configured to receive and store datapackets transmitted by each of the plurality of sensor underlaymentunits. In another aspect, a data analysis device can be configured toreceive the stored data packets, compare the measured zone capacitancevalues associated with one of the plurality of sensor underlayment unitsto previously-measured zone capacitance values transmitted by the samesensor underlayment unit and generate a result therefrom. In a furtheraspect, the data archival device and the data analysis device can beembodied in the same physical entity.

In another implementation of the present disclosure, a system fordetermining flooring performance is provided. The system for determiningflooring performance comprises a plurality of sensor underlayment unitswherein each sensor underlayment unit further comprises a sensor andprocessing unit as described previously and a power supply busconfigured to supply the plurality of sensor underlayment units withpower. Additionally, the system comprises a data analysis deviceconfigured to receive data packets originating at each of the pluralityof processing units as well as compare the measured zone capacitancevalues from each of the plurality of sensors with previously-measuredzone capacitance values transmitted by the same sensor underlayment unitand generate a result therefrom. Optionally, the system for determiningflooring performance can comprise a data archival device configured toreceive and store the data packet and as described previously.

In another aspect, it is contemplated that the system for determiningflooring performance can comprise a sensor underlayment unit comprisinga plurality of sensors and a processing unit operably connected to theplurality of sensors, as described previously.

In operation, for example, a 22 foot by 9 foot flooring comprising aplurality of flooring samples can be installed in a room for testing perapplicable ASTM test methods. Here, a system for determining flooringperformance can be installed beneath the flooring in a grid pattern sothe actual foot event locations and total number of footfall events perlocation can be measured and recorded. The untrafficked flooring samplescan be measured on an imaging device at least one preselected viewingangle prior to testing. It is further contemplated that the imagingdevice can comprise, for example and without limitation, a camera, aflatbed scanner, a spectrometer, a laser scanner and the like. Inoperation, the flooring sample can be subjected to a selected number offoot strikes, followed by measurement and comparison relative to theun-trafficked flooring sample, in order to determine how many footstrikes the carpet can absorb without a noticeable change in color ortexture.

In another aspect, the threshold change in at least one of color andtexture can be measured using at least one of spectral and imageanalysis of the flooring sample both before and after the induced foottraffic wear. In light of the present disclosure, one skilled in the artwill recognize and appreciate that this comparison can be, for exampleand without limitation, a spectral color change analysis such as DECMC,a photo-based pixel comparison, a 3-D image and depth analysis, and thelike. In another aspect, the threshold change in at least one of colorand texture can be about 2.0 DECMC units.

In another aspect, the change in at least one of color and texture canbe expressed as a percentage relative to the measurements of theuntrafficked flooring samples. Here, using the RGB colorspace method toillustrate, a selected group of pixels corresponding to substantiallyidentical locations on the untrafficked and trafficked samples can beaveraged and compared. In one aspect, the maximum of each value (i.e.,R, G, and B) can be subtracted from the minimum of each value, thensummed and expressed as a % change relative to the values measured forthe untrafficked sample alone. It is contemplated that a thresholdchange as expressed as a % change relative to the measured values forthe untrafficked sample can be from about 5% to about 25%.

In another aspect, a spectrometer can be used as the imaging device.Here, the spectrometer can comprise a non-contact spectrometer. It iscontemplated that the non-contact spectrometer can be configured tomeasure the L, a, and b color values of each flooring sample. Controlsamples can be unworn samples of the same flooring type as the flooringsample and can be used to determine a delta L, a delta a, and a delta bas well as a DECMC 2:1 value.

Accordingly, the Figure and the corresponding text provide a number ofdifferent components and mechanisms for determining flooringperformance. In addition to the foregoing, implementations describedherein can also be described in terms acts and steps in a method foraccomplishing a particular result. For example, a method for determiningflooring performance is described with reference to the components anddiagrams of the Figure.

Here, a method for determining flooring performance can compriseinstalling a foot strike detection assembly; installing a flooring fortesting comprising a plurality of flooring samples on top of the footstrike detection assembly; measuring a selected untrafficked sample withan imaging device at least one preselected angle; providing a means forinducing foot traffic wear; subjecting the selected flooring sample to aselected number of foot strikes; measuring the selected traffickedsample with a an imaging device at the at least one preselected angle;comparing the selected untrafficked sample measurements to the selectedtrafficked sample measurements; and determining the number of footstrikes the selected sample can absorb until a threshold change in atleast one of color and texture occurs. In a further aspect, the methodcan further comprise the step of improving carpet construction toimprove resistance to color and texture change induced by foot traffic.In another further aspect, the method can further comprise forecastingthe expected lifespan of the tested flooring in relation to otherflooring products. In a further aspect, the means for inducing foottraffic wear can be, for example and without limitation, a human walkerwalking on the flooring to induce foot traffic wear, at least onerobotic foot walking on the flooring to induct foot traffic wear, andthe like.

In other implementations, the present disclosure provides for a methodfor measuring the number of foot strikes a flooring sample can absorbuntil a threshold change in at least one of color and texture occurscomprising providing a spectrometer having an incident light beam,providing a flooring sample for measurement, providing a control samplehaving a control pile direction, determining a flooring sample piledirection, orienting the flooring sample with respect to thespectrometer such that the incident light beam is preferentiallyoriented relative to the sample pile direction, measuring the flooringsample at preselected angles to determine the viewing angle thatproduces the greatest color change as compared to the control sample. Ina further aspect, the preselected angles can be 22.5 degrees, about 30.0degrees, and about 45.0 degrees. In even further aspects, themeasurement can be repeated with differing pile directions.Additionally, the method can further comprise a laser scanning apparatusknown in the art to map the worn carpet topography and calculate loss ofheight and tuft integrity.

Thus, implementations of the foregoing provide various desirablefeatures. For instance, the foot strike detection assembly andassociated methods can reduce testing cost and produce results that aremore accurate with regard to real-world use. In another instance, animproved method of measuring and comparing relative flooring sampleperformance is provided that provides consistent and repeatable readingsto determine flooring wear.

The present invention can thus be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed aspects are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

What is claimed is:
 1. A system comprising: a floor covering disposed in an area; and a sensor underlayment unit disposed below the floor covering and comprising: a plurality of sensors, wherein each sensor of the plurality of sensors has a plurality of zones associated therewith and is configured to measure a value of at least one parameter in at least one of the plurality of zones associated therewith; and a processing unit communicably coupled to the plurality of sensors and configured to receive the value of the at least one parameter and generate and transmit a data packet comprising the value of the at least one parameter upon occurrence of a change in the value of the at least one parameter in the at least one of the plurality of zones associated with at least one of the plurality of sensors; and a data analysis device configured to receive the data packet and determine an event of a footfall on the floor covering in the area and a location of the footfall in the area based on the value of the at least one parameter of the data packet.
 2. The system of claim 1, wherein to determine the event of a footfall, the data analysis device is configured to compare the value of the at least one parameter of the data packet to previously-measured parameter values associated with the sensor underlayment unit.
 3. The system of claim 1, wherein the plurality of sensors are arranged in a grid pattern.
 4. The system of claim 1, wherein the plurality of sensors are arranged in a light curtain assembly.
 5. The system of claim 1, wherein the plurality of sensors comprise less than 10 sensors per square meter of the area.
 6. The system of claim 1, wherein the data analysis device is further operable to forecast an expected lifespan of the floor covering based on the value of the at least one parameter value and previously-measured parameter values associated with the sensor underlayment unit.
 7. The system of claim 1, wherein the data analysis device is further operable to predict field performance of the floor covering based on the value of the at least one parameter and previously-measured parameter values associated with the sensor underlayment unit.
 8. The system of claim 1, wherein a footprint of each sensor of the plurality of sensors ranges from about 1 square inch to about 144 square inches.
 9. The system of claim 1, wherein the plurality of zones comprises 2 to 12 zones.
 10. A system comprising: a floor covering disposed in an area; and a sensor underlayment unit disposed below the floor covering and comprising: a sensor having a unique identifier and a plurality of zones, the sensor being configured to measure at least one parameter value in at least one of the plurality of zones; and a processing unit operably coupled to the sensor and configured to receive the at least one parameter value and generate and transmit a data packet comprising the at least one parameter value from the sensor and generate and transmit a data packet comprising at least the unique identifier of the sensor and the at least one parameter value; and a data analysis device that is communicably coupled to the processing unit and configured to receive the data packet, and compare the at least one parameter value of the data packet to previously-measured parameter values associated with the sensor underlayment unit to determine an event of a foot strike on the floor covering in the area and that the foot strike is a unique foot strike.
 11. The system of claim 10, wherein the data analysis device is configured to transmit the data packet upon occurrence of a change of the at least one parameter value in the at least one of the plurality of zones of the sensor.
 12. The system of claim 10, wherein the sensor comprises at least one of a pressure plate capacitance sensor, a capacitance thin film sensor, a retro-reflective optical sensor, a force sensitive resistor sensor, a membrane keyboard sensor, a piezoelectric thin film sensor, a hall effect sensor, a surface acoustic wave sensor, a strain gauge sensor, or a pressure switch sensor.
 13. The system of claim 10, wherein the data analysis device is further operable to forecast an expected lifespan of the floor covering based on the at least one parameter value and previously-measure parameter values associated with the sensor underlayment unit.
 14. The system of claim 10, wherein to determine whether the foot strike is unique, the data analysis device is configured to compare a time stamp of the data packet to a time stamp of at least one other data packet comprising the previously-measured parameter values.
 15. A system comprising: a sensor underlayment unit, comprising: a plurality of sensors, wherein each sensor has a unique sensor identifier and a plurality of zones, wherein each of the plurality of sensors is configured to measure a value of at least one parameter in at least one of the plurality of zones; and a processing unit operably connected to the plurality of sensors and configured to receive the value of the at least one parameter from at least one of the plurality of sensors and generate and transmit a data packet comprising at least the unique identifier and associated value of the at least one parameter from at least one of the plurality of sensors upon occurrence of a change in the value of the at least one parameter of that sensor; a data archival device configured to receive and store the data packet transmitted by the sensor underlayment unit; and a data analysis device configured to compare the value of the at least one parameter from the data packet to previously-measured parameter values associated with the same sensor and generate a result therefrom.
 16. The system of claim 15, further comprising a power supply bus operably connected to the sensor underlayment unit.
 17. The system of claim 15, wherein the processing unit is configured to wirelessly transmit the data packet.
 18. The system of claim 15, wherein the data archival device further comprises a wireless receiver.
 19. The system of claim 15, wherein the data analysis device is operable to determine if the value of the at least one parameter is the result of a singular external event.
 20. The system of claim 15, wherein the plurality of zones comprises from about 2 to about 8 zones. 